My modification project with pics

bootlegbbq · Last edited by bootlegbbq on Mar 29 2010; edited 2 times in total

I'm a cooker not a fabricator so I'm very nervous about chopping up my smoker in the hopes that I have a better cooker. However, I realize I waste a tremendous amount of wood using a burn barrel and want to get your thoughts on my ideas for modification. Based on the dimensions of the cooker 6' by 30" and using the "calculator" I believe I will need a firebox 2'x2'x29.5" with a 2'x6" gap between the firebox and cooking chamber. One concern I have is the size of the smoke stack. My intention is to create a reverse flow smoker so I would keep the smoke stack on side away from the firebox closed at all times but I'm concerned the smoke stack on the firebox side is too small to create the draw I need. Your thoughts would be greatly appreciated.
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joshsheff1 · Posted: Feb 19 2010 Post subject:

I'm not sure what size your exhaust is, but based on your pics. it does look a lil small. What's the diameter of the pipe?
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bootlegbbq · Posted: Feb 20 2010 Post subject: My modification project

joshshef1 the existing exhaust is 4" diameter x 2'. The calculator calls for 8" x 17". I'm wondering if I can just add another 4" exhaust placed on top of the cooker?
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day_trippr · Posted: Feb 20 2010 Post subject: Re: My modification project

bootlegbbq · Posted: Feb 20 2010 Post subject: My modification project

Wow. Glad I asked. When we get started I'll post more pictures. Sorry for the formatting. This was my first time posting pictures. I think I figured out the problem and will open a new, more user friendly post next time. Thanks!
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day_trippr · Posted: Feb 20 2010 Post subject: Re: My modification project

bootlegbbq · Posted: Feb 20 2010 Post subject: My modification project

Thanks day_trippr. Now on to the build.
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bootlegbbq · Posted: Mar 10 2010 Post subject:

day_trippr...I just realized the measurement on my existing smoke stack is 4"OD and 3 1/2" ID. Will this change your calculations?

On the location of the firebox, I already have an existing opening where the coal drawer pulls out of the cooking chamber. Does the top of the firebox need to be within a certain distance to the top of the existing opening?
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day_trippr · Posted: Mar 11 2010 Post subject:

A 3.5" ID stack doubled up with a second stack of the same ID would be equivalent to a single 5" ID stack. Using your earlier cook chamber & firebox dimensions, the spreadsheet recommends that a 5" ID stack should be 43" tall. Should be doable, I'd think.

As for the firebox-to-cook chamber connection: the optimum would have the top of the firebox opening as near as possible to the top of the firebox, to minimize if not eliminate any hindrance to outflow. And the top of the opening into the cook chamber (ie: the same elevation AGL) would be at the ideal height of a tuning or reverse-flow plate - which in turn would be at the ideal spacing to the bottom cooking grate.

So the "best" answer to your question is a bit more complex than fitting the firebox to an existing hole in the cooker...

Cheers
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bootlegbbq · Posted: Mar 11 2010 Post subject:

Thanks for your help day_trippr. You've answered all my questions, some of which I probably should have figured out Embarassed

Since this is not something I do on a regular basis it is good to have you're input. Smile

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bootlegbbq · Posted: Mar 29 2010 Post subject:

OK...Here we go. Got the firebox tacked in 24x24x29.5

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4170.jpg
Got the air vents mocked...ironically we changed this mock up later. My help is inspecting the inside of the firebox for potential hiding places.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4172.jpg

The door is mocked and ready for the plasma cutter on Monday.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4173.jpg

Uh oh...wife and twins are calling. More pics to come.
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bootlegbbq · Posted: Mar 29 2010 Post subject:

Next we needed to trim some from the back of the trailer. We also had to unbolt the cooker and move it over 2 inches to accommodate the new firebox.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4175.jpg

After that, Cliff used a cutting torch to make way for the smoke to move into the cooking chamber. At this point I got really nervous but having seen all the builds on the Smokering helped calm my nerves.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4176.jpg
I guess we're committed at this point. No turning back now.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4177.jpg
What hole? Cliff did a nice job on plugging the hole from the previous vent.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4178.jpg

The firebox goes to the plasma cutter on Monday, the remainder of my supplies (9 gauge expanded metal, 3/4 square tubing for the firebox grate, and tuning plates for the cooking chamber) are due Tuesday so I might be able to test this thing by next weekend. So far I've got $350 in materials plus the many racks of ribs I'll owe Cliff once this is completed, not to mention what I will owe my mechanic for letting us use his space and equipment for the modification.
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bootlegbbq · Posted: Mar 31 2010 Post subject:

OK, I got my door and vents cut out but the guy who cut it out wasn't listening when I told him not to cut the corners completely out so that I could attach the hinges before completing the cut. Any thoughts on the best way to move forward so that my hinges work properly?
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bootlegbbq · Posted: Mar 31 2010 Post subject:

So I got the firebox back from the plasma cutter, not too happy about the door being cut off but we'll figure something out.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4183.jpg

After a few more cuts and tweeks we got her mounted and tacked into place.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4185.jpg

Hmmm...didn't think of that. Embarassed

We'll have to cut the braces on both sides and move them to the back of the firebox. Find a problem, fix a problem. I guess you really cant plan for everything.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4184.jpg

It was a bit harry getting the back plate to fit, not sure we should have done that last but Cliff worked it out.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4188.jpg

Tomorrow we will work on the grate for the firebox and maybe the tuning plates. Shelves are welded into place.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4180-1.jpg
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bootlegbbq · Posted: Apr 01 2010 Post subject:

Our vent has been cut, grinded (is that a word), and tacked into place.

http://i997.photobucket.com/albums/af93/bootlegbbq/100_4198.jpg

It's all about having the right tools!

http://i997.photobucket.com/albums/af93/bootlegbbq/100_4199.jpg

Cliff used a piece of angle iron to hold his torch steady while he cut a piece of channel iron into two pieces of angle iron. Waste not want not...I'm on a budget!

http://i997.photobucket.com/albums/af93/bootlegbbq/100_4201.jpg

I can see by the lack of posts that this is not a very interesting build for you guys but I gotta tell ya, I'm having a blast! Big thanks to joshshelf1 for posting his pics. I took a lot of info from that build. Also, big thanks to K.A.M. for his builds. They gave me the confidence to go forward with this. Can't wait to continue tomorrow! Very Happy

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k.a.m. · Posted: Apr 01 2010 Post subject:

bootlegbbq, your rebuild is looking fantastic y'all are doing some mighty fine work Very Happy

I am watching your progress and look forward to seeing some more pics.
If you are talking about your fire box door being cut loose before the hinges were attached, I would have gone the same way. Mounting hinges on a fixed door and then cutting it loose spells misery because they will almost always sag on you. It is better to kick the door up a bit then weld out the hinge to compensate for the sag in material. At least this is how I approach the idea.
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bootlegbbq · Posted: Apr 01 2010 Post subject:

Thanks K.A.M....I had it all wrong. I was under the impression it was better to weld the hinges on, then finish cutting the door. Thanks for the input.
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Ya know how ya git to Carnegie Hall don't cha...practice

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bootlegbbq · Posted: Apr 05 2010 Post subject:

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4202.jpg

Cliff had to cut a chunk out so we could get the tuning plates in. We'll weld it back into place once all the plates are in and fitted.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4215.jpg

I was really glad to see the tuning plates in. It came as a light at the end of the tunnel. This has been a long process from the planning stages til now and we've got a ways to go but I think we're on the home stretch now.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4216.jpg

Our next project is going to be getting this 6" exhaust pipe cut and welded on the smoker. I've decided to put one on both ends so that i can use the cooker as a reverse flow but also as a tuning plate model when the need arrives. Both exhausts will be 40 inches in height. Thanks again daytripper for helping me out with this.

http://i997.photobucket.com/albums/af93/bootlegbbq/Modification%20March%202010/100_4213.jpg
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Ya know how ya git to Carnegie Hall don't cha...practice

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joshsheff1 · Posted: Apr 06 2010 Post subject:

Looking good bootlegbbq Cool

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zysmith · Posted: Apr 06 2010 Post subject:

Not sure if I will ever build my own but I love to look at everyone's projects.

Nice job!
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